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FREQUENTLY ASKED QUESTIONS OR COMMENTS ON BOILERS
Dear Potential Customer: Low Volume Operator Exempt boilers have been marketed in Ontario to eliminate the requirement for Operating Engineers in specific applications. This can be accomplished if the following conditions are met. Operating water content in each boiler does not exceed 75 imperial gallons, and the total operating water content of all boilers in the plant, does not exceed 250 imperial gallons. To achieve these conditions manufacturers of boilers have had to design special boilers to perform under these conditions, which are now classified by TSSA as Low Volume Boilers. In meeting the Low Volume conditions, manufacturers have had to compromise on fundamental design features of traditional boilers. Some of these changes are as follows. 1. 2. 3. 4. 5. 6. 7. 8. 9. Reduction of Heating Surface area Reduction of Steam drum space Increasing heat transfer area, by adding baffling to transfer heat. On many designs this has resulted in higher electrical blower motor consumption Reduction of number of gas passes. This normally has results in lower combustion efficiencies Increase in normal conventional boiler blow down rates to achieve good quality steam Compacting boiler tube design, not allowing for ease of tube replacement. Designing burners with set flame control to overcome potential tube stress from inadequate internal water circulation. Higher burner Purge Loss using Step Fired Burner concepts, versus Full Burner Modulation as found in conventional boilers Poor control of Water Treatment Chemicals in the boiler. Some Low Volume Boilers designs do not have a good location for obtaining a representative water sample, to control proper chemical control. Compromise of Steam Quality resulting in many issues including Efficiency Loss.
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The above points are some of the issues that will be addressed in this report to follow
Some Low Vol. Design Boilers 100 BHP = 314 sq feet 150 BHP = 486 sq feet 175 BHP = 596 sq feet 200 BHP = 596 sq feet 250 BHP = 753 sq feet 300 BHP = 753 sq feet
100 BHP = 150 BHP = 175 BHP = 200 BHP = 250 BHP = 300 BHP =
Pick the boiler with the Higher Heating Surface . (Fill in the above and compare)
Gas Passes Fill in & Compare Note: Some manufacturers use an economizer to recover heat loss, due to not having a high gas pass number. Economizers are an additional cost and have potential problems such as low life expectancy, if inadequate Water Treatment control is not maintained at all times. Pick the boiler with the Highest Gas Pass without the use of an economizer.
Why? No boiler operates under these conditions. Review the manufacturers literature or ask them how they arrived at their efficiencies. Request the data they use to arrive at their efficiency. Example: Feed Water Temperature: F Operating Pressure Psig Ask the manufacturer to supply Efficiency based on the following Feed Water Temperature 180 F or at your Feed Water Temperature Operating Pressure you will be running at Psig Suddenly claims of 85% Efficiency will no longer be valid. Make the manufacturer responsible for any false claims, in the event of a purchase of equipment does not match the claimed manufacturer efficiency. Pick the boiler which gives a True Higher Efficiency
Tube Replacement
One of the most significant costs after fuel, to operate a boiler is maintenance expenses. As boilers normally last for many years and only require tube replacement, depending on water treatment conditions and heat release / stress factors, owners should consider in their purchase evaluation, the cost of tube repairs and replacement.
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On some L.V boilers all the tubes can be replaced without welding. All tubes are ferruled requiring no welding procedures. Pick the Boiler were the least welding is required to install tubes.
Pick the boiler with the Highest Turndown ratio. (Fill in & Compare)
Purge Loss
Reduce Purge loss by picking the boiler with the Highest Turndown ratio. Purge loss is the loss expected when a boiler shuts off and restarts sending the heat in the boiler up the stack. This heat loss is not recovered. Purge Losses from ASME guidelines are as follows 2 Purge Times / hour boiler shutdown = 2% efficiency Loss 5 Purge Times / Hour boiler shutdown = 8% efficiency Loss 10 Purge Times / Hour boiler shutdown = 30% efficiency Loss
EXAMPLE: If the boiler is 100 BHP The boiler having 2:1 turndown will shutdown when the load is below 50 BHP A similar boiler with a 4:1 turndown will shut off when the boiler load is below 25 BHP And a boiler with a 8:1 turndown will shut off when the load is below 12.5 BHP
Some L.V boilers the turndown is standard at 4:1 and higher ratios of (8:1) are available. Pick the boiler with the Highest Turndown ratio.
Steam Quality:
A. B. C. D. E. F. G. Good quality steam is one of the factors normally neglected, when reviewing boiler purchase. It is one of the most important issues, as poor steam quality results in the following. Lower steam temperatures at the process. Longer process time. Higher blow down rates as boiler feed water is contaminated with high solids in condensate Potential for heat stress on tubes, due to low water conditions. Fouling of heat exchanger with boiler water solids and contaminants Fouling of steam pipes. Fouling of steam traps resulting in high energy losses, and higher trap maintenance. System efficiency loss, resulting in higher fuel usage.
Some L.V Boilers have been tested in the field and provides excellent steam quality under most load conditions. Do not rely on the manufacturer claims, test it for yourself, or have it done by an independent source, such as your Water Treatment Specialist. Always pick the boiler giving the Best Quality Steam.
Modems:
Some manufacturers provide a modem, attached to the boilers, to relay information back to the manufacturer. This concept is unique and has advantages and disadvantages. Having an independent modem monitor, could reduce your in house liabilities. This is available using other equipment rather than the boiler supplier network.